Racor Filter Division Europe

Super Impactor Crankcase Ventilation Separator

Crankcase Ventilation - Super Impactor

Diesel Engine Emission Control High Performance Crankcase Separator Systems for the future
With over 20 years experience in crankcase filtration Parker Racor Filter Division Europe, a part of Parker Hannifin, the global leader in motion control technologies, has been developing new innovative high efficiency technology for crankcase emission control. Parker introduce the new benchmark for ultra high performance, fit for life, closed crankcase ventilation solutions. The Super Impactor CCV eliminates environmental pollution from crankcase emissions, allowing open and closed crankcase circuit solutions at >98% efficiency, with no service element. Smaller, lighter, more economical and with higher efficiencies than its closest rivals, the systems also include the ultimate crankcase pressure regulator offering the tightest crankcase pressure control. Crankcase blow-by is produced when combustion gases under high pressure are blown passed the piston rings into the crankcase. Laden with oil these gases must be allowed to exit the engine to prevent pressure build up and seal failure. The control of diesel engine blow-by has become an important topic with the progressive reduction of NOX, Hydrocarbon and particulate in the global legislation. By enforcing emissions targets, legislators have committed engine and vehicle manufacturers to find the technological advancements necessary to control blow-by venting and minimize impact on human and environmental health. For achievement of current Euro / EPA directives, Closed Crankcase Ventilation systems are employed to return cleaned blow-by gas to the engine air intake system. The tighter demands for future legislation means that further step changes in engine design will be applied and the performance requirements for CCV systems will become yet more demanding.

Super Impactor Key Features

Outlet to air intake Turbo boost air inlet

Crankcase blow-by inlet Modular bracket mountings to suit your application Integrated upstream patented pressure regulator

Oil drain to engine sump with inline check valve

Super Impactor Performance

The Parker Super Impactor Si3 has been tested under laboratory conditions as well as in field trials. The performance graphs below show that the Si3 exhibits exceptional separation efficiencies across the key aerosol size distribution ranges seen in crankcase blow-by, both when an engine is run at rated Power and Torque but also across the engine speed and power output range. Typically the Si3 will remove upstream blow-by aerosol oil challenge, reducing it to below 0.2g/hr down stream of the Si3 depending upon application. The Si3 has been validated on current and future Euro / EPA compliant engines and demonstrates tight crankcase pressure regulation control across all engine conditions and turbo depressions, the graph to the right shows crankcase pressures across the engine speed and load range for a Typical Tier 4/Euro 6 engine.

Super Impactor Engine Routing

Exhaust Turbine Turbo Compressor

Turbo air inlet <1%

(from after intercooler)

Engine Air Intake Filter

CCV Super Impactor Si3

CCV Inlet

Oil Drain Check Valve (CCV55279)

An example of a typical engine routing that incorporates a Racor air filter and also a Racor Super Impactor (not shown to scale.)

Super Impactor Configurator

Box 1 Box 2 Box 3 Box 4 Box 5 Box 6

Si
1 Product Si - Super Impactor 2 Impactor Type 3 - Fully Variable

200

RCR

1
6 Oulet Orientation 1 - 0 deg 2 - 72 deg 3 - 144 deg 4 - 216 deg 5 - 288 deg

3 Blow By Flow Rate 100 - 0 to 100 lpm 200 - 0 to 200 lpm

5 Crankcase Blow By Inlet Orientation 1 - 30 deg 2 - 90 deg 3 - 150 deg 4 - 210 deg 5 - 270 deg 6 - 330 deg

4 Brand RCR - Racor OEM branding available

Mounting and Orientation

Inlet spigot mounting orientation (box 5 on configurator above).

Outlet spigot mounting orientation (box 6 on configurator above).

Super Impactor Installation

10 o 10 o Note: The maximum mounting orientation angle is 10 o.

4 x M8 cap head fixings

10 o

10 o

Super Impactor Port Positions

Super Impactor inlet from crankcase

Super Impactor outlet to air intake

Turbo air from inlet manifold

Note: The minimum installation height is recommended to be 60cm above sump oil level.

Oil drain to sump with inline check valve 5

Super Impactor Specifications

Specifications Maximum Flow Rate Port Sizes Inlet (Hose Connection) Outlet (Hose Connection) Turbo boost inlet (SAE J2044) Oil drain outlet (Hose Connection) Weight in grams (without check valve) Crankcase Regulation Pressure Max Operating Temperature

Si3100 100 lpm

Si3200 200 lpm

26 mm 26 mm 10 mm 13 mm 920 g

26 mm 26 mm 10 mm 13 mm 920 g

+ / - 10 mBar
- 40 deg C to + 180 deg C

Super Impactor Kits - For Fuel Sump Drain Lines

The Super Impactor has kits available that ensure you can utilise the Super Impactor in many engine applications.
Part Number K0647-6-8 CCV55279 1 / 4 - M14DC8UBV Description Hose Barb Check Valve Elbow Union

Installation Instructions
The Super Impactor is very much a plug and play device follow the simple guide below for easy installation.

Compressed Air from Inlet Manifold COMPRESSED AIR FROM INLET MANIFOLD

Drain Hose Orientation DRAIN HOSE ORIENTATION

Quick QUICK CONNECT Connect

NO U BENDS IN

SAE 10mm FemaleCONNECT SAE 9.89mm FEMALE QUICK Quick Connect No U Bends in Drain Hose NO U BENDS IN DRAIN HOSE Inlet Hose Orientation INLET HOSE ORIENTATION No U Bends in NO Hose Inlet U BENDS IN INLET HOSE Outlet Hose Orientation OUTLET HOSE ORIENTATION

NO U BENDS IN No U Bends in OUTLET HOSE Oulet Hose

Trouble Shooting
If the Super Impactor fails to separate oil from the blow-by gas ensure that the check valve has been installed in the correct orientation. If the check valve has the incorrect orientation, flip the check valve around and re-start the engine. If problems persist do not hesitate to contact Racor Technical Support: Tel No: +44 (0)1924 487000 Fax No:+ 44 (0)1924 487001 Email: filtrationinfo@parker.com RFTC@parker.com

Customer Interface Drawings

Super Impactor 3

Front View

Side View

Super Impactor 3

Top View

Top View 156

207

Please note that drawings are not to scale in comparison to each other.

227

Superimpactor Development History - OEM Focus

The major OEMs for heavy duty engines have found a solution for fit for life crankcase ventilation in oil driven or electrically powered centrifuges. The oil driven centrifuge is complex, relatively costly and requires significant integration into the engine block. This has left the medium duty value sensitive market with lower cost filter solutions with mediocre efficiency and short life servicing intervals. Tier IV engine deliveries start to ramp up. Whilst the Super Impactor is achieving up to 95% gravimetric efficiency the technology has been advanced and optimized using mathematical modeling, CFD analysis, Particle Image Velocimetry, and empirical analysis methods. With a simple modular construction the technology can now include multi-stage impaction reaching up to 98% efficiency or secondary stage submicron filtration achieving in excess of 99% efficiency. The Super Impactor Technology will be available for medium, heavy, and industrial sized engines controlling blow-by gas up to 1000litres per minute whilst maintaining crankcase pressure limits and efficiencies throughout the engine life. The cleaned gas can be closed to the intake system and high separation efficiency prevents damage to turbo compressors and intercooler systems. Alternatively the cleaned gas can be returned to atmosphere and satisfy the total engine emission regulations of the future. The technology enables the return of separated oil back to the crankcase sump and provides long lasting prevention of oil consumption. A great advantage of this development is its malleability and potential for engine integration. The core technology can be integrated into an engine valve cover or other accompanying equipment; such technical solutions are currently being developed in Europe and the USA. Much of the development work has been carried out in-house in Parkers state of the art development facilities in West Yorkshire (UK), but Parker have also partnered with The University of Leeds who have been instrumental in producing key optimised legacy data and software which has enabled the engineers to meet tough development challenges. This information was originally written by Adrian Mincher, R&D Engineer, Racor Filter Division Europe for Engine Technology Magazine.

Current Production Phase 1-Super Impactor

From 2006 the Parker Racor, UK based R&D team initially investigated a simplified competitive centrifuge system driven via compressed air. Whilst early testing was positive, subsequent innovation and engineering theory accentuated the possibility to increase aerosol velocities greater than 100m/s without the use of rotating parts. Primary focus was on taking a small amount of turbo air and using that energy to raise the separation efficiency of an inertial impactor. This technology which is fit for life, flexible in design and light weight has been named the Super Impactor and the first production version went onto production engines in May 2010 with volume deliveries commencing when Tier IIIb and

Bespoke engine Super impactor valve cover integration

Racor Crankcase Filtration Filter Coalescer Range

In a robust, compact package, the Racor Closed Crankcase Ventilation (CCV) Filter Systems provide superior oil coalescence and crankcase pressure control under the most severe conditions. CCV systems eliminate crankcase emissions and provide a cleaner engine environment by performing the functions below: They reduce oil consumption by separating the oil from crankcase gases and returning the oil to the sump. The high-efficiency filter prevents fouling of the turbocharger and aftercooler. Keeps engine compartment and components clean. Filtered crankcase gas is returned to the engine intake system for re-combustion instead of polluting the environment.

CCV Operation
CV systems operate by filtering C contaminants and coalescing oil mist from crankcase gases. The crankcase breather hose is connected to the 3/4" inlet hose barb of the CCV assembly. The connection at the engine can be positioned at the valve cover or crankcase. iltered air from the CCV F assembly is plumbed to the air intake system between the air filter and turbocharger. oalesced oil drains from the C filter sump to an external drain. A check valve holds oil in the line until it is released to the oil pan via a hose connection. he pressure regulating valve T protects the engine from excessive crankcase vacuum. The only routine maintenance required for the Racor Closed Crankcase Ventilation filter system is filter replacement. Typical service life of the highperformance filter in diesel applications is 750 hours. Some variations in service life occur depending on load profile, engine wear condition, flow, aerosol mass concentration of crankcase emissions, and soot concentration.

Specifications Maximum Flow Rate Maximum Engine Rating Inlet/Outlet Port Size Weight (approx,) Replacement Filter Media Density: Low Replacement Filter Media Density: High Replacement Filter Media Density: Ultra Housing Material Crankcase Pressure Regulator Bypass/Change Indicator Engine Block Check Valve Return Fitting Swivel Fitting (Qty.) Oil Drain Hose I.D.

CCV4500 10 CFM (283 LM) 400 HP (298.3 KW) 1 3/16-12 STOR 3.3 lbs (1.5 kg) CCV55248-04 CCV55248-08 CCV55248-10 Die cast head, glass-filled nylon and black powder epoxy-coated steel bowl. Integral Integral or Remote 1/4 NPT #6 JIC (2 pcs.) 0.375 in. (0.95 cm)

CCV6000 20 CFM (566 LM) 800 HP (596.6 KW) 1 5/8-12 STOR 5.0 lbs (2.3 kg) N/A CCV55274-08 CCV55274-10 Die cast head, glass-filled nylon and black powder epoxy-coated steel bowl. Integral Integral or Remote 1/4 NPT #6 JIC (2 pcs.) 0.375 in. (0.95 cm)

CCV8000 40 CFM (1133 LM) 1600 HP (1193.1 KW) 1 7/8-12 STOR 8.7 lbs (3.9 kg) N/A CCV55222-08 CCV55222-10 Die cast head, glass-filled nylon and black powder epoxy-coated steel bowl. Integral Integral or Remote 3/8 NPT #8 JIC (2 pcs.) 0.5 in. (1.27 cm)

CCV12000 50 CFM (1416 LM) 2000 HP (1491.4 KW) 1 7/8-12 STOR 9.3 lbs (4.2 kg) N/A CCV55222-12-08 CCV55222-12-10 Die cast head, glass-filled nylon and black powder epoxy-coated steel bowl. Integral Integral or Remote 3/8 NPT #8 JIC (2 pcs.) 0.5 in. (1.27 cm)

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Units can be manifolded to handle higher flow rates. Do not use CCV1500 in continuous duty applications.

Racor Filter Division Europe Fuel Filtration

Racor has quality-certified manufacturing, engineering, and distribution in place around the world, so no matter where you are you can rely on Racor to solve tough filtration problems from the refinery to the engine. Over the years, Racor has kept pace with the increasing demands of fuel filtration, from tough engine

The Most Advance Fuel Delivery Systems in The World

requirements for ever-finer particle removal efficiencies and longer life, to the effective processing of ULSD and biodiesel. The heart of these advances is in Racors proprietary engineered filter media families. Our selection of Aquabloc medias are known worldwide for their combination of high efficiency, long life and unsurpassed water-removal performance, meeting and exceeding the challenges of todays diesel engine requirements in all markets and environments.

Air Filtration
superior performance ease of service and unmatched customer satisfaction. Over the years, Racor has kept pace with the increasing demands of air filtration, from tough engine requirements to longer life. Our engineers collaborate with customers to design a solution that provides installation flexibility, ECO III is the newest addition to Racors complete ECO family of air filtration systems. ECO systems can be configured to meet a wide range of on-theroad, off-road, and industrial applications.

Protect Your Equipment and Environment

From ECO Series to a custom designed air filtration system, Racor provides an innovation solution to exceed customer expectations. Racor is the most trusted name in engine protection. Why trust your investment to anything else?

Oil Filtration
Racor engineers have designed a new generation of top load filters to meet the requirements of todays oil-controlled, high pressure fuel injection systems. Racor media meets the variable geometry and variable nozzle turbocharger requirements. An uncompromising, high level of fluid cleanliness is needed to achieve operating efficiency and reach service life. The environmentally-friendly cartridge oil filters are crushable, incinerable and cost-effective to replace.

Engineered Solutions For Your System

The Racor Bypass Oil Series removes dirt, varnish, ash, tar, soot and other contaminants that fullflow filters cannot remove from your engines oil and hydraulic systems. The system also removes condensed water, which forms componentdamaging acids if left in the oil. The Racor Bypass Oil Series removes 99.5% of damaging contaminants to minimize wear and extends engine component life.

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Catalogue: FDRB538UK 09/2011

Parker Hannifin Manufacturing (UK) Ltd. Racor Filter Division Europe Tel: +44(0)1924 487000 Email: filtrationinfo@parker.com www.parker.com/rfde Your local authorized Parker distributor